Advanced Wastewater Treatment Technology Mechanical Vapor Recompression and Membrane Polishing

Presented to

10th Annual Chemical Management Services Workshop San Francisco, California

John Burke Director of Engineering Services Houghton International

Page 1

Introduction

What is this new wastewater treatment technology? How does it fit within an existing manufacturing facility? How does each step work, and work together? Cost Comparison Advantages to Chemical Managers Summary

Page 2

Basic Issue With Wastewater Treatment

Manufacturing Facility Wastewater Wastewater Treatment Two Waste By-products Cost Waste- To Water Discharge

Waste Water Treatment System

Aluminum Processing Facility

Both are Regulated

One waste stream becomes two waste streams

Used Oil Sludge

Cost To Haul

Page 3

Advanced Waste Treatment Makes Sense

Manufacturing Facility Wastewater Fluid Recycling System Two commodity Byproducts

Water For Re-use

AWWT

Only one is Regulated

Used Oil One waste stream becomes two commodities For Sale

.
Page 4

Design Objective
Treat any oil-like liquid, both water dilutable and not, such as from aluminum metalworking fluids, detergents and similar process fluids Separate the water phase for re-use Separate the oil-like phase for sale. Oil-like materials can be from mineral, vegetable and animal origin.

Why ?

Economic benefits One less regulatory issue to worry about. Improves environmental image, both internally and externally

Page 5

What are Some of the Contaminants in Aluminum Metalworking Wastewaters?

Increasing Solubility
Page 6

Hydrocarbon Products (Floatable, Suspended / emulsifiable, and Settleable Organics) Petroleum Oils, Vegetable Oils, Animals Oils, Waxes, Fatty Acid Soaps (Ca, Fe, Al), Chlorinated Esters and Paraffins Floatable, Suspended, and Settleable Solids Graphite, Vibratory Debur, Floor Dirt Metals Iron , Aluminum, Copper, Lead, Chrome, Zinc, Nickel, Manganese, Molybdenum Non-metals Arsenic, Selenium Dissolved Solids Salts (Sodium and Potassium Salts) Dissolved Organics Amines, Amides, Esters, Glycols, Surfactants, Detergents, Fatty Acids, Fatty Alcohols, Antimicrobials, Phosphate Esters

Common Treatment Approaches

Chemical treatment Salt Splitting Polymer with / without salt splitting Membrane Separation Ultrafiltration Microfiltration Combined Technologies Chemical / Biological Membrane / Biological Membrane / Biological / Membrane Membrane / Membrane ( UF/RO or UF/NF)
Page 7

Issues With Common Treatment Approaches

Chemical Inflexible on various wastes Requires skilled Operator Creates salts within the process Membrane (single) Membrane sensitive to fouling Salts and metals pass through membrane Biological Not every chemical is readily biodegradable Industry is moving toward bio-stable chemistries Combined Technologies Issues are generally compounded, not reduced High Reject rates
Page 8

Product Rate to Reject Rate

Manufacturing Facility Wastewater Wastewater Treatment Two Waste By-products

Waste Water Treatment System

Aluminum Processing Facility

Product 98%

WasteWater

Reject 2%

Used Oil Sludge

Page 9

So What is Mechanical Vapor Recompression?

1. 2. 3. 4.

Distillation, Followed by Mechanical Compression of the Distillate Recovery of the Heat into the Boiling Zone Condensing of the Vapor HEAT
Compressor
Mechanical Vapor Recompression

Heat Exchanger

HEAT

Output (Warm Condensate)

HEAT
Page 10

Conventional Distillation /Condensation Model

Vapor

Heat Exchanger Input Boiling Vessel

Heat Removed
Cold Water IN Warm Water Out

Heat Added

Heat Removed
Output (Warm Condensate)

Page 11

Conventional Mechanical Vapor Compression Distillation Model

Vapor Vapor Compressor More Heat Added

Heat Heat Recovered Exchanger Input Boiling Vessel

Heat Added

Heat Removed
Output (Warm Water Condensate)

Page 12

Current Technology Basic Thermal Evaporation

Purpose: Concentrate waste by evaporating water using thermal energy

Page 13

Basic Thermal Evaporation

Two forms of energy required to boil water: a. Raise water to boiling ( 212 Degrees F ) Sensible heat ( 1 BTU required to raise one pound of water one degree F) b. Turn water into steam at 212 degrees F ) Latent Heat (960 BTUs required to turn one pound of water at 212 degrees F into steam vapor at 212 degrees F)

Page 14

Basic Thermal Evaporator Model

960 BTUs/ to turn one pound of water into vapor ALL LATENT HEAT LOST

HEAT 50% VAPOR

Overall Process Efficiency = 50%

Vapor Zone

LOST HEAT 50%

Wastewater
Wastewater - in

HEAT 100%
Concentrated Wastewater - out

Page 15

Basic Mechanical Vapor Compression Evaporator Model

HEAT VAPOR Vapor Zone Wastewater

Wastewater in

HEAT

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Basic Mechanical Vapor Compression Evaporator Model

HEAT VAPOR Vapor Zone Wastewater

Wastewater in

HEAT

Page 17

Basic Mechanical Vapor Compression Evaporator Model

HEAT VAPOR Vapor Zone Wastewater

Blower or Fan (Compressor)

More heat added

Wastewater in

HEAT

Page 18

Basic Mechanical Vapor Compression Evaporator Model

HEAT VAPOR

Blower or Fan (Compressor)

More heat added

Heat Exchanger #1

Vapor Zone Wastewater

Reclaimed Heat (Latent)

Condensed Vapor (hot)

Wastewater in

HEAT

Page 19

Basic Mechanical Vapor Compression Evaporator Model

HEAT VAPOR

Blower or Fan (Compressor)

More heat added

Heat Exchanger #1 Condensed Vapor (hot) Heat Exchanger #2

Vapor Zone Wastewater

Reclaimed Heat (Latent)

Wastewater - in

Reclaimed Heat (Sensible)

HEAT

Condensed Vapor out (warm) to Ultrafilter

Page 20

Basic Mechanical Vapor Compression Evaporator Model

HEAT VAPOR

Blower or Fan (Compressor)

More heat added

Heat Exchanger #1 Condensed Vapor (hot) Heat Exchanger #2

Vapor Zone Wastewater

Reclaimed Heat (Latent)

Wastewater - in

Reclaimed Heat (Sensible)

HEAT

Condensed Vapor out (warm) to Ultrafilter

Concentrated waste Oil / water - out

Page 21

Output (Hot Vapor)

VAPOR HEAT
Conventional Evaporation

HEAT
Compressor
Mechanical Vapor Recompression

Heat Exchanger

HEAT
960 BTUs/ to turn one pound of water into vapor

HEAT

Output (Warm Condensate)

1 BTUs to raise one pound of water one degree Fahrenheit

Page 22

Cost Comparison Conventional Evaporation VS. Mechanical Vapor Recompression

Energy Required to Treat 1,000 Gallons of Oily Wastewater

Conventional Evaporation @ 50 % Efficiency

Mechanical Vapor Recompression As Measured

15,936,000 BTUs

920,833 BTUs

(16.2 X less energy)

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Lab Test Evaporation / Condensation Unit

Page 24

20 Gallon Per Minute Unit

Page 25

Influent Feed Pump

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Primary Heat Exchanger

Page 27

Secondary Heat Exchanger

Page 28

Recirculating Pump

Page 29

Progressive View of Sample Concentration

Less than 1% oil

80% oil

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Starting Sample

Concentrate from MVR 99.7 % Volume Reduction

Salable Oil

Page 31

Treatment Process Steps

1. 2.

Storage and flow equalization Emulsified oil, most soluble organics, metals, and fine solids separation (Mechanical Vapor Recompression Distillation System) Trace insoluble organic separation ( Ultrafilter System)

3.

Page 32

Overall Flow Schematic

Return water to Manufacturing Processes Water Virgin Lubes, Chemicals, Etc. Evaporative Losses

Manufacturing Processes Rolling oils, washers, etc.

Industrial Wastewater From Plant

Primary Wastewater Storage Mechanical Vapor Recompression System

Day Tank

MVR
Oil Reject

Day Tank

Ultrafilter U F

Day Tank

Dilute Oil Reject Tank Tank Used oil - out Decant water

Page 33

Basic Ultrafilter Model - Flow Schematic

Treated Effluent Permeate Wastewater (influent From MVR
For Re-use 10 PSI

Concentrate
Membrane Surface Day Tank
Clean Tank 120o F

Ultrafilter
45 PSI

Feed

Pump Pump
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To Oil Reject Tank

Ultrafilter 50 Gallons Per Minute

Page 35

Starting Sample

Condensed Distillate From MVR

Polished Sample After Ultrafilter

Page 36

Design Objective
Must Meet the The Basic Requirement 1. Does it fit with the Personality of the Organization?
All Mechanical System No Chemicals (Defoamer, UF Detergent) Industry Common Components Blowers Pumps Heat Exchangers Automatic Valves Steam Traps Easily Automated Easy to Trouble Shoot Energy Efficient

Page 37

System Performance
Influent
BOD5 COD Oil and Grease TPH TKN TDS TSS Fe Zn Cu Pb Ni pH
Page 38

Effluent
200 - 400 400 - 650 < 10 < 5 < 20 < 20 < 0.1 < 0.01 < 0.01 < 0.01 < 0.01 < 0.01 7.0 7.5

5,000 20,000 500 250 200 5,000 3,000

10,000 35,000 _ 5,000 3,500 400 10,000 6,000 300 15 5 2 1 8.0 8.8

System Performance Operating Cost Comparison

Cost ( $ USD) / 1000 US Gallons Method Chemical Methods Chemicals Electricity $ 1.00 $ 2.00 $ 5.50 Total $ 5.00 $ 7.00 $ 10.55 65 / 35 $ $ $ 3.00 5.00 8.55 70 / 30 4.00 99 / 1

NOR $ 4.00 WOR $ 5.00 WOR+ ATR $ 5.05 Product / Reject Ratio

Membrane Methods NOR $ 0.50 WOR $ 1.50 WOR+ ATR $ 1.55 Product / Reject Ratio MVR/ UF WOR + ATR $ 0.00 Product / Reject Ratio

$ 2.50 $ 3.50 $ 7.00

$ 4.00

NOR = No oil recovery WOR= With Oil recovery ATR = Ability To Recycle Water phase back into the process
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Energy cost assumed at $ 0.05 / kilowatt-hour

Benefits to Chemical Managers

Allows the use of more complex metalworking fluids and detergents. Can be applied where water is scarce Can be applied where discharge to local sewer is restricted Can be added on to existing treatment (only MVR required?) Turns oil into a commodity (adds value). Easily Automated.
Page 40

Summary
Advantage One waste stream becomes two commodities.

Water For Re-use

AWWT
Used Oil One waste stream becomes two commodities For Sale

.
Page 41

Thank You

Contact Information John Burke Houghton International 27181 Euclid Ave. Cleveland, Ohio 44094 USA Office Phone Cell Phone Fax Phone Email
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216-289-3991 216-235-1995 216-235-3991 jburke@houghtonintl.com